Alexander Gurr Posted October 15, 2011 Share Posted October 15, 2011 Guys, I am in the throws of getting the old girl ready for her first fire up and need to fill the gearbox (standard 5 speed). I just want to check the filler plug location....the manual is very vague. Is it drivers side next to the lowest cutout in the transmission tunnel? Cheers, Alex Link to comment Share on other sites More sharing options...
Martin J Posted October 15, 2011 Share Posted October 15, 2011 No passenger side, & if your car is the same as mine (metric chassis sigma) you can only access it from underneath & you will need a cut down allen key. Right pig to get to....I used a flexi hose with a funnel attached. Link to comment Share on other sites More sharing options...
ECR Posted October 15, 2011 Share Posted October 15, 2011 5 speed type 9 filler/level plug is on the passenger side .... Link to comment Share on other sites More sharing options...
Alexander Gurr Posted October 15, 2011 Author Share Posted October 15, 2011 Thanks guys.....the only thing I can see on the passenger side is a metal disk about 2" in diameter with no obvious cut out for an allen key to go into....it seems to be filled with mastic or sealant of some sort. Any ideas? Cheers, Alex Link to comment Share on other sites More sharing options...
Grubbster Posted October 15, 2011 Share Posted October 15, 2011 It is almost impossible to see from under the car, there is a lip on the gearbox and it is just above that, you need a friend with thin fingers who doesn't mind the taste of gearbox oil to help Does this help you locate it? http://inlinethumb47.webshots.com/49646/1089320959048831359S600x600Q85.jpg Edited by - Grubbster on 15 Oct 2011 17:35:51 Link to comment Share on other sites More sharing options...
Michael Downing Posted October 15, 2011 Share Posted October 15, 2011 Alex, it's on the passenger side, near the front, roughly where the passenger's feet are, above a lip at the bottom of the gearbox. Mine is also a new delivery, and it had a square socket that kind of took a 3/8" drive when the gearbox was out. I couldn't get the driver in alongside the gearbox when it was installed in the transmission tunnel though, so mine is just finger tight at the moment. If you find a way to tighten it, do let me know. Link to comment Share on other sites More sharing options...
mav Posted October 15, 2011 Share Posted October 15, 2011 You can use an easibleed to fill the gear box too, saves messing about with funnels and lengths of hose Link to comment Share on other sites More sharing options...
Grubbster Posted October 15, 2011 Share Posted October 15, 2011 Another view I found that shows where the filler plug is http://duncansknives.users.btopenworld.com/images/caterham/029_engine_ready_to_install.jpg Link to comment Share on other sites More sharing options...
richy Posted October 15, 2011 Share Posted October 15, 2011 Happy memories - trying to balance the plug on the tip of your fingers at 1am on a freezing winter's night with dripping gear oil making it so easy to hold on to 😬 Good luck Alex Link to comment Share on other sites More sharing options...
Domus Posted October 15, 2011 Share Posted October 15, 2011 Cut a short piece off an allen key (twice the socket depth) Stick it in with some grease, then use a spanner. Good luck Link to comment Share on other sites More sharing options...
Michael Downing Posted October 15, 2011 Share Posted October 15, 2011 Quoting Domus: Cut a short piece off an allen key (twice the socket depth) Stick it in with some grease, then use a spanner. Good luck Can't do that now. Mine has a square socket for the filler plug ☹️ Ho hum. Link to comment Share on other sites More sharing options...
Alexander Gurr Posted October 15, 2011 Author Share Posted October 15, 2011 Thanks guys. I found it, ground down a allen key and got it out. I have just spent the last couple of hours with a contraption Heath Robinson would be proud of to fill the gearbox up. I got lord knows how much oil in the gearbox and a very good quantity on the floor. I am guessing I probably got about a litre in, but really am not sure. When it goes in for its post build inspection I will get Caterham to check it as I am really paranoid about having enough in there Link to comment Share on other sites More sharing options...
Grubbster Posted October 15, 2011 Share Posted October 15, 2011 Easiest filling tool I know (credit goes to Weeman for this) of is about 18" of copper plumbing pipe with a 90 degree bend soldered on with just a short piece of pipe in the other side - you can manoeuver the short end into the gearbox from above, then stick a funnel in and fill it! No easy way to get the filler plug in afterwards though. Link to comment Share on other sites More sharing options...
BBL Posted October 16, 2011 Share Posted October 16, 2011 If you ever have the cover removed for any reason in the future, I recommend this mod: welding a O2 bung into the front left corner of the cover: http://i321.photobucket.com/albums/nn384/BBL-Sean/7%20Build%20Issues/Gboxtop1.jpg Oh, and the filler plug is on the driver's side of my car (LHD). Link to comment Share on other sites More sharing options...
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